Patent Application
20200284036
The present application claims priority to a provisional patent application No. 63/813,613, filed on Mar. 4, 2019 entitled Debris Flashing Especially for Tile Roofs, disclosure of which is included herein at least be reference.
The present invention is in the field of construction materials including roofing materials and pertains particularly to methods and apparatus for protecting a roof valley from debris.
In the roofing construction trades, roofing materials generally include some form of flexible underlay layer of protective covering beneath shingles or tiles or other primary roof coverings. specialty flashing is typically utilized to further protect underlying structural portions of the roof from moisture. One common form of roofing system is the flat tile roof. A flat tile is often made of a material like a cement formed into tiles. Tiles may also be made of fired clay material or a variety of other materials. Such flat tile roofs are typically thicker than slate shingles and asphalt shingles.
The greater thickness dimensions of tiles can be problematic at the valley locations on a roof. For example, the way tiles are laid, upper tiles over lower tiles, creates a gap space beneath the upper tile and lower tile where debris may be blown in and become lodged. At the valley locations, tiles are typically cut so that the tiles can come close to the valley and overlie valley flashing, which is often referred to in the art as a ribbed valley. The relatively large gap space under the flat tiles is accessible to debris entering laterally as these tiles terminate at the valley flashing.
Typical flashing material provides an extra layer of protection between the tile under-surface and the wood however, in a tile ribbed valley, water and debris may be blown into the gap spaces. Leaving such debris lodged beneath the tiles invites further debris clogging and eventual passage of the debris past the flashing edge leaving only the roof flexible sheet overlay as a last barrier between the debris and raw wood material of the roof. The problem is expounded in roof structures with relative low pitches.
To avoid the problem of debris collection under valley roof tiles, periodic maintenance is required. It is known in the prior art to fight against this problem with flat tile roof by following techniques like periodic removal of tiles adjacent to the valleys in the roof and manually cleaning out any debris which has collected within these gaps.
While generally effective, this is a complex procedure, and it is hard to determine whether such a procedure is necessary or not, and how often it should be performed since the gaps cannot be easily studied to determine how full they are of debris. Furthermore, repeated cleaning cycles performed on a roof may cause damage over time to the roof underlay material and the tiles themselves.
Therefore, what is clearly needed is a flashing component that restricts or blocks debris access into gaps left between over laid roof tiles.
Accordingly, a flashing overlay system for overlaying roofing materials occupying a roof valley is provided and includes multiple planar flashing units having at least one first non-planar feature, the flashing units arranged in pairs including a left flashing unit and a right flashing unit, the flashing unit pairs covering the roofing materials occupying the roof valley along the length and track of the roof valley, the paired flashing units abutted together along the edges of the planar material supporting the at least one first non-planar feature, the first non-planar features aligned generally with the center line of the roof valley, the left flashing units disposed left of center and the right flashing units disposed right of center, and at least one elongated saddle strip folded over at longitudinal center and clamped over, fastened over, or otherwise fitted over the abutted first non-planar features of the multiple planar flashing units paired together and overlaying the roofing materials occupying the roof valley.
In one embodiment, the flashing units are metallic sheets of aluminum or galvanized steel. In another embodiment, the flashing units are polymeric sheets rated for protection against ultraviolet radiation. In one embodiment, the roofing materials covered by the flashing system are roofing tiles. In a preferred embodiment, the multiple flashing units each include a second non-planar feature having a three side box structure contiguously formed therefrom or formed separately and pivotally attached thereto, the second non-planar feature disposed proximal to the bottom edge of each flashing unit in correct overlay orientation, the open end of the box structures fitted over or clamped over the lower edge or edges of the roofing materials overlaid by the flashing units.
Accordingly, a flashing overlay system is provided. This system includes a first edge of the planar material, the first edge including a rib feature formed orthogonally to the planar surface and extending upward from the planar surface, the feature formed substantially along the length of the first edge, a second edge of the planar material extending substantially laterally from the top end of the first edge, a third edge of the planar material extending substantially downward and toward the bottom end of the first edge of the planar material, and a fourth edge of the planar material, the fourth edge substantially shorter in length than the first, second, or third edges, the fourth edge substantially parallel with the second edge and bridging the bottom of the third edge to the bottom of the first edge, the fourth edge including a wind clip anchoring feature pivotally attached to the fourth edge or contiguously formed off of the fourth edge.
In one embodiment, the planar flashing unit functions as a left-side flashing unit in a pair of flashing units arranged adjacently over a roof valley. In this embodiment there is a planer flashing unit functioning as a right-side flashing unit in a pair of flashing units arranged adjacently over a roof valley. In a variation of this embodiment, the rib feature along the first edge tapers down in height from the proximity of the top end of the first edge to the proximity of the bottom end of the first edge.
In one embodiment, the flashing unit further includes a pair of vertically aligned through openings placed through the planar material of the flashing unit for accepting fasteners, the top opening proximal to the second edge and the bottom opening proximal to the fourth edge, wherein an invisible vertical center line running through the openings is substantially perpendicular to the fourth edge. In one embodiment, the rib feature includes one or more snap pin recesses distributed on the internally facing side of the rib feature adapted to accept snap pins on the overlaying wall of a saddle strip.
In one embodiment of the flashing overlay system, the elongated saddle strip cover comprises a single sheet of flashing material custom cut to length equal to or just greater than the length of the roof valley taken along the center line of the roof valley, the flashing material creased or folded over along longitudinal center to form the saddle configuration to cover the rib features of the flashing units. In another embodiment of the flashing overlay system, the elongated saddle strip cover is shorter in length than the roof valley requiring more than one saddle strip cover to cover the overall length of the rib features. In a preferred embodiment of the flashing overlay system, the first non-planar features aligned generally with the center line of the roof valley abut at left and right rib features, wherein the rib features are clamped, snapped together, or otherwise fastened together beneath the saddle strip cover.
In various embodiments described in enabling detail herein, the inventor provides a unique flashing system comprised of unique left and right flashing units tied together to cover and protect the underlying gap spaces under overlaying roofing materials installed in a roof valley from receiving laterally directed wind-blown debris and water. The present invention is described using the following examples, which may describe more than one relevant embodiment falling within the scope of the invention.
It is a goal of the present invention to provide a protective tile flashing overlay system of individual flashing units that are configured to be placed over relatively flat tiles adjacent to a valley in the roof. Another goal of the present invention is to provide a flashing overlay system that effectively prevents laterally driven debris from entering gap space between upper and lower tiles. It is a further goal of the present invention to provide a flashing overlay system that reduces or eliminates the periodic requirement of tile removal and replacement to access debris clogs beneath the tiles.
In this embodiment, valley flashing units 101a and 101b are mirror imaged parts (left, right) having non-planner features oriented in a same direction to produce a left valley flashing unit and a right valley flashing unit. A single valley flashing unit 101a or 101b may be fabricated from aluminum sheet or stainless or galvanized steel sheet materials typically used for roof flashing. In one embodiment, valley flashing units 101a and 101b may be fabricated of a durable and weather resistant polymeric material, hydrocarbon material, or composite materials thereof, the polymeric material having a sufficient UV (ultra violet radiation) protection rating against sun damage and, if required, a heat/cold coefficient factor for polymeric roof materials. In the case of metallic material use, valley flashing units 101a and 101b may be left plain or without finish, painted or coated, or otherwise powder coated, sand blasted, etc.
Valley flashing units 101a and 101b include at least two non-planer features. Valley flashing units 101a and 101b are substantially triangular parts in profile, the units including a short fourth side or edge defining one of the non-planer features formed at one of the corners. Valley flashing units 101a and 101b include at least two non-planer features. For example, one edge of a valley flashing unit 101a or 101b (mirror image) is formed or bent upward along the edge to create a rib feature extending at least relatively orthogonally upward from the triangular plane of the unit. This feature allows left and right units to be laid side-by-side over the tiles 102 where the orthogonally extending ribs meet substantially at the center of the valley. Valley flashing system 100 includes a flashing system saddle strip cover 107 that is configured to fit over the adjacent and interfacing rib features on the valley flashing units interfacing edges, effectively tying the valley flashing units together.
Another non-planer feature of valley flashing units 101a and 101b is in the form of a wind clip structure, which may be provided at a lowermost corner relative to orientation of the units in a roof valley. The wind clip structure is strategically located at the lower corner of valley flashing units 101a and 101b. The wind clip structure is adapted by bending or forming to fit over the lower edge of a tile 102 being covered. This non-planar feature may exhibit a three-sided box like cross-section in side-elevation profile, the feature extending downward to cover the thickness of the tile and then rearward to fit underneath the tile being covered.
In one embodiment, the wind clip feature is provided as a separate component riveted to or otherwise rotably attached to the flashing unit so that it may pivot somewhat relative to the rest of the valley flashing unit. A wind clip fits over the lower edge of the tile being covered and provides an anchor point for keeping the valley flashing unit from bowing upward or flapping due to strong winds. The wind clip feature has an inside diameter just larger than or equal to a thickness dimension of the lower edges of the flat tiles to be covered by the flashing product. Preferably, the lowermost corner of the flashing product is truncated so that this corner defines a very short fourth side of the main triangular planar surface of the flashing product. This short fourth side is typically about 1.5 to 2.0 inches in length. The wind clip preferably has a similar length as this short fourth leg at the truncated lower corner of the flashing unit 101a or 101b.
In this view, a top edge 103a extends laterally to the left of rib feature 104a forming an acute angle B with the edge supporting orthogonal rib feature 104a. Angle B may be about 80 degrees but may be smaller than 80 degrees or as large as a right angle or up to 90 degrees without departing from the spirit and scope of the present invention. Edge 103a is the top lateral edge of the valley flashing units 101a and 101b of
A third edge 102a of valley flashing unit 101a forms an acute angle A of about 45 degrees from the end of edge 103a and edge 102a extends downward and toward the lower end of rib feature 104a. In this embodiment, rib feature 104a extends upward orthogonally from the generally triangular flat plane of the flashing unit. Wind clip feature 105a may be a separate component attached to valley flashing unit 101a or it may be cut and then formed at the lower corner end of the unit as is depicted in this embodiment. Wind clip feature 105a presents on the side opposite of the orthogonal rib feature 104a. The wind clip feature is substantially shorter than other sides of the flashing unit. The fourth short truncated edge of the triangular profile of valley flashing unit 101a may be about one- and one-half inches or two inches long. In one embodiment the fourth short truncated edge supporting the wind clip feature 105a may be roughly parallel to edge 103a.
In this embodiment, edge rib feature 104a may be about 19 inches in length. In this embodiment, the laterally extended edge 103a may be about 22 inches in length, and the longest edge 102a may be about 26 inches in length. In one embodiment, larger flashing units may be provided having larger overall dimensions. Likewise, smaller units may be created having smaller overall dimensions than those depicted in this example. In one embodiment, valley flashing unit 101a is laid on the left side of a roof valley over the left-of-center tiles as depicted in
In one embodiment, openings 106a may be provided through the planar portion of the material to accept fasteners though it is not required to practice the invention. The flashing system may be otherwise secured to the roof tiles by the weight of the tiles acting on the underlying top lateral edges of a flashing unit, by the wind clip features tucked under the lower tile edges of the covered tiles, and by the saddle strip connecting the mirrored flashing units at the center-line of the roofing valley.
The orthogonal height of rib feature 104a may be at least one and a quarter inch in height at the lowest end (if tapered) and up two a few inches in height at the upper end of the rib feature 104a. In one embodiment, rib feature 104a is uniform in height along the length and provides enough orthogonal material to define an interfacing wall with enough height to accept a saddle strip placed there over like saddle strip cover 107 described in
In one embodiment, rib feature 104a may be shorter than the length of the side of the flashing unit supporting it such as by being cut down at an angle to the surface of the flashing unit. For example, equal length angle cuts may be provided at both ends of the rib feature that extend down at an angle such as 45 degrees for example to the flat planner material of the flashing unit. The previously described saddle strip cover 107 of valley flashing system 100 of
In this view, wind clip feature 105a presents beneath the planar material of the flashing unit as a three-sided box open toward the upper end of the flashing unit relative to roof valley orientation. Wind clip feature 105a has an inside diameter C that is the same as or just larger than the thickness of the lower edge of the tile flashing unit 105a is covering. In one embodiment, wind clip feature 105a is a separate component that is attached to the planar material of flashing unit 101a in a manner enabling the wind clip to pivot somewhat about the point of attachment. In one embodiment, wind clip feature 105a may be adapted as a spring clamp that anchors each flashing unit to the tile it covers.
Side 103a of flashing unit 101a extends laterally away from the top of the rib feature 104a wherein side 103a is the top edge of the flashing unit in roof valley orientation. This top edge has a 9-degree taper or there about off a 90-degree angle from the top end of the rib feature. Angle B may be approximately 81 degrees. Top edge 103a is tucked under the bottom edge an upper adjacent tile or tile set. The very top valley flashing unit 101a has side 103a tucked under a roofing ridge-cap or another flashing strip if the valley terminates before the ridge line of the roof so the top edge 103a is never left exposed.
Openings 106a may be provided for fasteners but are not required to practice the invention or to secure a valley flashing system like system 100 of
Saddle strip cover 107 may have a standard cut length E representing a factory length that may be trucked and conveyed to a roof top along with other roofing materials. In one embodiment, saddle strip cover 107 may be provided in material rolls and may be cut and formed as needed in custom lengths that may be desired. Saddle strip cover 107 has an overall height D of approximately one and one-quarter of an inch. The broken line is intended to represent thickness of the saddle strip cover material, which may be identical in thickness to the planar flashing material of flashing units 101a and 101b. A flat strip before center folding may be up to two and one-half inches wide. However, dimensions may vary according to the actual materials used in a roof valley installation.
In one embodiment, a valley may be longer than a standard length of saddle strip cover 107. In such a case more than one saddle strip may be linearly installed starting from the lower end of the valley and working up. In the case of multiple saddle strips for a single valley flashing system like system 100 of
The gap between the opposing walls at the bottom of the strip may be about one-quarter of an inch. This gap may in actual practice be larger or smaller without departing from the spirit and scope of the invention. In one embodiment, the side walls of saddle strip cover 107 are not straight but curved in or pinched over at least the top one half of the height of the adjacent rib features of the flashing units. In another embodiment, the side walls of a saddle strip might be adapted to snap over or otherwise enabled to be fastened to or through the adjacent rib features firmly holding the rib features together in a manner that does not affect the function of strip cover 107 of preventing moisture or debris from entering through the gap between adjacent rib features. For example, the rib features may include one or more snap pin recesses distributed on the internally facing side of the rib features, the recesses adapted to accept snap pins protruding orthogonally from the overlaying inside interfacing wall of a saddle strip in saddle configuration.
Also, in one embodiment, adjacent rib features may be fastened to one another to firmly tie two valley flashing units together firmly, where the saddle strip cover 107 is also fastened to the rib features, or not fastened to the rib features. It is noted herein that when structures of the invention are identified as being coupled together or tied together, such language should be interpreted broadly to include the structures being coupled directly together or coupled together through intervening structures. Such coupling may be permanent or temporary depending on the type of fastener system employed. Such coupling may be affected in a rigid fashion or in a flexible fashion which allows pivoting, sliding or other relative motion of parts in the system while still providing some form of anchor attachment.
It will be apparent to the skilled person that the arrangement of elements and functionality for the invention is described in different embodiments in which each is exemplary of an implementation of the invention. These exemplary descriptions do not preclude other implementations and use cases not described in detail. The Uses and methods depicted within this description are purely emblematic of definitive ways in which to build and operate this invention and are not to be understood to be limiting of scope in any way. While the uses and methods have been described with a certain degree of particularity, it is to be noted that many alterations could be made in the details of the construction and the arrangement of the apparatus and its components without departing from the spirit and scope of this invention. It is implied that the uses and methods are not limited to the examples represented in this specification for the purpose of clarification and persuasion. The invention is limited only by the breadth of the claims below.
| Number | Date | Country | |
|---|---|---|---|
| 62813613 | Mar 2019 | US |
